Materials handling vehicle operating system comprising remedial indicator tags

ABSTRACT

A materials handling vehicle operating system is provided comprising a tag layout where a plurality of entry/exit tag sets are arranged along a travel path at different ones of the entry/exit thresholds of a restricted navigation zone. Each entry/exit tag set comprises a release tag, a restriction tag, and an indicator tag. The indicator tag is positioned between the restriction tag and the restricted navigation zone. The restriction tag is positioned between the release tag and the indicator tag. The tag reader and the reader module cooperate to compare identified tag data with stored tag data and initiate a remediation operation when an indicator tag is identified in place of a restriction tag. Tag layouts for one-way and two-way travel into and out of a restricted navigation zone are also contemplated.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to currently pending patent applicationSer. No. 16/202,385 filed Nov. 28, 2018, which claims the benefit ofProvisional Patent Application Ser. No. 62/592,123 filed Nov. 29, 2017.

BACKGROUND

The present disclosure relates to materials handling vehicle operationand, more particularly, to materials handling vehicle operating systemsthat are equipped for restricted operation in restricted zones of awarehouse. For the purposes of defining and describing the concepts andscope of the present disclosure, it is noted that a “warehouse”encompasses any indoor or otherwise covered facility in which materialshandling vehicles transport goods including, but not limited to,warehouses intended primarily for the storage of goods, such as thosewhere multi-level warehouse racks are arranged in aisles, andmanufacturing facilities where goods are transported about the facilityby materials handling vehicles for use in one or more manufacturingprocesses.

The present disclosure relates more particularly to optimizing the useof radio frequency identification tags (RFID tags), or otherconventional or yet-to-be developed readable-tag technology, in a taglayout to assist with vehicle navigation in a warehouse. For example,and not by way of limitation, U.S. Pat. No. 9,658,622 and US PG Pub. No.2016/0327952, describe the use of tags in various locations in a taglayout to affect vehicle navigation in the warehouse.

BRIEF SUMMARY

According to the subject matter of the present disclosure, a materialshandling vehicle operating system is provided where remedial indicatortags are introduced to address tag reading or sensing errors, potentialtag failure, and potentially missing tags in a tag layout of a materialshandling vehicle operating system.

In accordance with one embodiment of the present disclosure, a materialshandling vehicle operating system is provided comprising a materialshandling vehicle, a tag layout, a tag reader residing on the materialshandling vehicle, a reader module, and a vehicle controller. The taglayout comprises a plurality of sequenced tags positioned along a travelpath comprising a restricted navigation zone. The restricted navigationzone comprises a plurality of entry/exit thresholds along the travelpath. The sequenced tags comprise a plurality of entry/exit tag setsarranged along the travel path at different ones of the entry/exitthresholds of the restricted navigation zone. Each entry/exit tag set ofthe plurality of entry/exit tag sets comprises a release tag, arestriction tag, and an indicator tag. The indicator tag is positionedbetween the restriction tag and the restricted navigation zone along thetravel path. The restriction tag is positioned between the release tagand the indicator tag along the travel path. The tag reader and thereader module cooperate to identify the release tags, the restrictiontags, and the indicator tags of the sequenced tags of the tag layout.The vehicle controller executes restricted or unrestricted operationalfunctionality of the materials handling vehicle in accordance with theidentification of restriction tags and release tags along the travelpath by the tag reader and the reader module. The tag reader and thereader module further cooperate to compare identified tag data withstored tag data and initiate a remediation operation when an indicatortag is identified in place of a restriction tag according to a sequencedportion of the stored tag data.

In accordance with another embodiment of the present disclosure, amaterials handling vehicle operating system is provided where therestricted navigation zone comprises an entry threshold and an exitthreshold along the travel path and the sequenced tags comprises anentry tag set arranged along the travel path at the entry threshold ofthe restricted travel zone and an exit tag set arranged along the travelpath at the exit threshold of the restricted navigation zone. The entrytag set comprises a restriction tag and an indicator tag. The exit tagset comprises a release tag. The indicator tag is positioned between therestriction tag and the restricted navigation zone along the travel pathand the restricted navigation zone is positioned between the indicatortag and the release tag along the travel path. The tag reader and thereader module cooperate to initiate a remediation operation when anindicator tag is identified in place of a restriction tag.

Tag layouts for one-way and two-way travel into and out of a restrictednavigation zone are also contemplated.

Although the concepts of the present disclosure are described hereinwith primary reference to RFID tags, it is contemplated that theconcepts will enjoy applicability to any technology that enables passiveor active tags, arranged in a warehouse in a particular layout, andcarrying or conveying specific identifying information, to be detectedand read by a materials handling vehicle navigating through thewarehouse.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The following detailed description of specific embodiments of thepresent disclosure can be best understood when read in conjunction withthe following drawings, where like structure is indicated with likereference numerals and in which:

FIGS. 1-4 illustrate materials handling vehicle operating systemsaccording to several alternative embodiments of the present disclosure;

FIG. 5 illustrates materials handling vehicle operating systemsconfigured for networked or cloud-based operation; and

FIG. 6 is a flowchart illustrating one non-limiting example of analgorithm that can be used to incorporate remedial indicator tags into awarehouse navigation routine.

DETAILED DESCRIPTION

Referring initially to FIG. 1, a materials handling vehicle operatingsystem 100 according to one embodiment of the present disclosure isprovided comprising a materials handling vehicle 20, a tag layout 30, atag reader 40 residing on the materials handling vehicle 20, a readermodule 50, and a vehicle controller 60. The materials handling vehicle20 comprises storage and retrieval hardware 22 and a vehicle drivemechanism 24. As is illustrated schematically in FIG. 1, the materialshandling vehicle 20 may comprise a conventional or yet-to-be developedautonomous or semi-autonomous materials handling vehicle or, morespecifically, a forklift comprising conventional or yet-to-be developedlifting forks, drive train, and forklift wheels suited for travel in awarehouse environment.

FIGS. 1, 2 and 4 illustrate alternative tag layouts 30, each comprisinga plurality of sequenced tags. The tags are positioned along one or moretravel paths P, which comprise a restricted navigation zone 70. Therestricted navigation zone 70 may be a relatively simple linear travelzone with opposed entry/exit thresholds 72, as is illustrated in FIGS. 1and 4, or a more complex restricted navigation zone 70 with more thantwo entry/exit thresholds 72 and one or more different curved or lineartravel paths P, as is illustrated in FIG. 2. The sequenced tags, whichare described in detail below with reference to the plurality ofentry/exit tag sets 32, can be secured to or embedded in the warehousefloor and can be configured to provide identification data to the tagreader 40 and reader module 50 passively or actively. For example, andnot by way of limitation, the sequenced tags may comprise passive oractive RFID tags and, in many cases will only be distinguishable only bythe tag identification data that they carry.

Each restricted navigation zone 70 illustrated in FIGS. 1, 2, and 4comprises a plurality of entry/exit thresholds 72 along a travel path P.Entry/exit tag sets 32 are arranged along the travel path P at differentones of the entry/exit thresholds 72. Each entry/exit tag set 32comprises a release tag 32R, a restriction tag 32X, and one or moreindicator tags 32 i. The indicator tags 32 i are positioned between therestriction tag 32X and the restricted navigation zone 70 along thetravel path (P). Similarly, the restriction tag 32X is positionedbetween the release tag 32R and the indicator tag 32 i along the travelpath P. In this manner, a materials handling vehicle 20 approaching therestricted navigation zone 70 will encounter the same ordered successionof tags regardless of which entry/exit threshold 72 is to be crossed inthe approach. Similarly, a materials handling vehicle 20 leaving therestricted navigation zone 70 will encounter the same ordered successionof tags regardless of which entry/exit threshold 72 is to be crossed ondeparture.

The aforementioned predictable ordered succession of sequenced tagsprovides a means by which the functionality of the aforementionedsequenced tags can be enhanced by associating an indicator tag with arestriction tag or, as is described in further detail below, with arelease tag. Generally, the indicator tag provides a means by which thelocation of the materials handling vehicle within the tag layout can beidentified and acts as a failsafe if one of the sequenced tags ismissing or misread, or fails to function correctly. The indicator tagscan be used to generate a missing/malfunctioning tag signal, and can beused to ensure that appropriate commands are carried out even if thereis a missing or malfunctioning tag.

More specifically, the tag reader 40 and the reader module 50 cooperateto identify the release tags 32R, the restriction tags 32X, and theindicator tags 32 i of the sequenced tags of the tag layout 30. Thevehicle controller 60 executes restricted or unrestricted operationalfunctionality of the materials handling vehicle 20 in accordance withthe identification of restriction tags 32X and release tags 32R alongthe travel path P by the tag reader 40 and the reader module 50. The tagreader 40 and the reader module 50 further cooperate to compareidentified tag data with stored tag data and initiate a remediationoperation when an indicator tag 32 i is identified in place of arestriction tag 32X according to a sequenced portion of the stored tagdata.

FIGS. 1 and 2 also illustrate the provision of additional indicator tags32 i adjacent to the release tags 32R of the sequence of tags. Morespecifically, in FIGS. 1 and 2, each entry/exit tag set 32 comprises anadditional indicator tag 32 i that is positioned such that the releasetag 32R is positioned between the restriction tag 32X and the additionalindicator tag 32 i along the travel path P. The tag reader 40 and thereader module 50 further cooperate to compare identified tag data withstored tag data and initiate the aforementioned remediation operationwhen an additional indicator tag 32 i is identified in place of arelease tag 32R according to a sequenced portion of the stored tag data,when an additional indicator tag 32 i is identified out of sequence inthe stored tag data, or when an additional indicator tag 32 i isidentified in direct sequence after a restriction tag 32X is identifiedin the stored tag data.

It is contemplated that the aforementioned remediation operation may beinitiated, for example, when an indicator tag 32 i is identified out ofsequence in the stored tag data. Alternatively, in another contemplatedembodiment, the remediation operation is initiated when an indicator tag32 i is identified in direct sequence after a release tag 32R isidentified in the stored tag data when a materials handling vehicle 20is approaching the restricted navigation zone 70. Alternatively, oradditionally, the remediation operation can be initiated when anindicator tag 32 i is identified in direct sequence after a restrictiontag 32X is identified in the stored tag data when a materials handlingvehicle 20 is leaving the restricted navigation zone 70.

Although a variety of conventional or yet-to-be developed remediationoperations may be practiced within the scope of the present disclosure,in one contemplated embodiment, the aforementioned remediation operationis initiated by generating a human and/or machine-readable remediationsignal. In other embodiments, the remediation operation comprises afault signal generation step, a transition to or from restricted orunrestricted operational functionality of the materials handlingvehicle, or a transition to operational functionality that is based on apredicted command associated with a missing tag from the sequenced tagsof the tag layout.

It is contemplated that the reader module 50 may comprise anyconventional or yet-to-be developed technology for facilitating a tagread operation and may reside on the materials handling vehicle 20, in alocation that is remote from the materials handling vehicle 20, or acombination thereof. It is also contemplated that the reader module 50may comprise a tag database holding the stored tag data. Alternatively,the reader module 50 may be configured to access a tag database holdingthe stored tag data. Similarly, the vehicle controller 60 may compriseany conventional or yet-to-be developed technology for facilitatingcontrol of the materials handling vehicle 20 and may reside on thematerials handling vehicle 20, in a location that is remote from thematerials handling vehicle 20, or a combination thereof.

The restricted navigation zone 70 may be characterized by a variety ofoperational restrictions including, for example, vehicle speedrestrictions, materials handling height restrictions, or a combinationthereof. The entry/exit thresholds 72 of the restricted navigation zone70 can be configured for two-way entry and exit, limited to one-wayentry, or limited to one-way exit. For example, in the one-way travelembodiment illustrated in FIG. 3, the restricted navigation zone 70comprises an entry threshold 72A and an exit threshold 72B along thetravel path P. The sequenced tags comprise an entry tag set 32A arrangedalong the travel path P at the entry threshold 72A of the restrictedtravel zone and an exit tag set 32B arranged along the travel path atthe exit threshold 72B of the restricted navigation zone 70. The entrytag set 72A comprises a restriction tag 32X and an indicator tag 32 i.The exit tag set 72B comprises a release tag 32R and, optionally, anadditional indicator tag 32 i. The indicator tag 32 i is positionedbetween the restriction tag 32X and the restricted navigation zone 70along the travel path P. The restricted navigation zone 70 is positionedbetween the indicator tag 32 i and the release tag 32R along the travelpath P. The vehicle controller 60 executes restricted or unrestrictedoperational functionality of the materials handling vehicle inaccordance with the identification of the restriction tag 32X and therelease tag 32R. The tag reader 40 and the reader module 50 furthercooperate to compare identified tag data with stored tag data andinitiate a remediation operation when an indicator tag 32 i isidentified in place of a restriction tag 32X according to a sequencedportion of the stored tag data.

In the one-way embodiment illustrated in FIG. 3, where the exit tag set72B is provided with the additional indicator tag 32 i, i.e., where therelease tag 32R is positioned between the restricted navigation zone 70and the additional indicator tag 32 i along the travel path P, the tagreader and the reader module can be configured to initiate a remediationoperation when the additional indicator tag 32 i is identified in placeof a release tag 32R.

As previously disclosed, the tag reader 40 and the reader module 50cooperate to compare identified tag data with stored tag data. In theembodiment illustrated in FIG. 5, where like structure is illustratedwith like reference numbers, a materials handling vehicle operatingsystem 100 according to the present disclosure is configured fornetworked or cloud-based operation. In FIG. 5, the reader module 50 andthe stored tag data reside in a remote computer 80 that communicateswith the materials handling vehicle 20 directly via a wireless networkconnection, indirectly via a data cloud 90, or both.

In various embodiments, a remote computer 80 may include, but need notbe limited to, a desktop, laptop, server, client, tablet, smartphone, orany other type of remote computing device. In one embodiment, the remotecomputer 80 includes at least one processor and memory (non-volatilememory and/or volatile memory). The remote computer 80 may furtherinclude one or more input devices which can include, by way of example,any type of mouse, keyboard, disk/media drive, memory stick/thumb-drive,memory card, pen, touch-input device, biometric scanner, voice/auditoryinput device, motion-detector, camera, scale, etc. The remote computer80 may include non-volatile memory (ROM, flash memory, etc.), volatilememory (RAM, etc.), or a combination thereof.

The data cloud 90 may facilitate communications over a wired network, awide area network, a local area network, a personal area network, acellular network, a satellite network, etc. Suitable local area networksmay include wired Ethernet and/or wireless technologies such as, forexample, WiFi. Suitable personal area networks may include wirelesstechnologies such as, for example, IrDA, Bluetooth, Wireless USB,Z-Wave, ZigBee, and/or other near field communication protocols.Suitable personal area networks may similarly include wired computerbuses such as, for example, USB and FireWire. Suitable cellular networksinclude, but are not limited to, technologies such as LTE, WiMAX, UMTS,CDMA, and GSM. The data cloud 90 can be communicatively coupled to anydevice capable of transmitting and/or receiving data via the network.Accordingly, the hardware of the data cloud 90 can include acommunication transceiver for sending and/or receiving any wired orwireless communication. For example, the data cloud 90 hardware mayinclude an antenna, a modem, LAN port, Wi-Fi card, WiMax card, mobilecommunications hardware, near-field communication hardware, satellitecommunication hardware and/or any wired or wireless hardware forcommunicating with other networks and/or devices.

The flowchart of FIG. 6 illustrates one non-limiting example of aparticular mode of operating the materials handling vehicle operatingsystem disclosed herein. In the illustrated example, upon startup of thematerials handling vehicle (see step 1), the reader module performs aguidance check (see step 2) to determine the location of the materialshandling vehicle within the tag layout. This guidance check can beperformed by first checking if the materials handling vehicle is in asaved aisle (see step 3). If there is a saved aisle, meaning there is anaisle in which the materials handling vehicle is known to be, withstored tag data, the reader module checks the last tag read, or the lasttag data saved (see step 4), and if there is no saved aisle, the aislelocation of the materials handling vehicle is unknown, or if there is nosaved tag data (for instance, if the materials handling vehicle wasturned off mid-aisle), the reader module will wait for the next tag readby the tag reader (see step 5). Once the tag reader reads a tag (seestep 5), or if there was tag data saved (see step 4), the algorithmbuilds an aisle list with a sequenced portion of stored tag data (seestep 6). The aisle list compiles a sequenced portion of the stored tagdata for the tag layout. If the saved tag data is valid, or is found,within the aisle list, the reader module waits for the tag reader toread a new tag (see step 8). If the saved tag is invalid, or is notfound, within the aisle list, the reader module checks that thesequenced portion of the stored tag data for the tag layout is correctby checking the tag index, or stored tag data for the tag layout (seestep 7). If it is a valid sequence, the reader module waits for the tagreader to read a new tag (see step 8). If it is an invalid sequence, thetag reader and the reader module initiate a remediation operation, whichmay include generating a fault signal (see step 10). This invalidsequence may be due to a tag missing or malfunctioning.

After waiting for the tag reader to read a new tag (see step 8), thereader module checks the new tag data by checking the tag index, orstored tag data for the tag layout (see step 9). If the new tag data isa valid sequence when checked against the stored tag data, the readermodule will wait for the tag reader to read a new tag (see step 8). Thisloop may continue indefinitely as long as there are no tags missing ormalfunctioning. After the reader module initiates a remediationoperation (see step 10) from an invalid sequence, the reader modulescompares the tag data from the last valid tag read to the stored tagdata and predicts the operational functionality command of the missingtag from the sequenced portion of the stored tag data (see step 11). Ifthe reader module is unable to predict the command, the materialshandling vehicle restarts (see step 1). If the reader module is able topredict the operational functionality command, a user may place thematerials handling vehicle's throttle in a neutral position (see step12), or may perform another mechanism, before the materials handlingvehicle achieves movement again. The reader module then clears the fault(see step 13).

In some cases, the reader module may predict the operationalfunctionality command (see step 11) and end the remediation operation(which may include clearing the fault signal generated, see step 13)without interfering with operation of the materials handling vehicle.After the reader module ends the remediation operation (see step 13), itthen waits for the tag reader to read a new tag (see step 8). Ifguidance is ever lost while waiting for the tag reader to read a new tag(see steps 8 or 5), the reader module performs a guidance check (seestep 2).

Having described the subject matter of the present disclosure in detailand by reference to specific embodiments thereof, it is noted that thevarious details disclosed herein should not be taken to imply that thesedetails relate to elements that are essential components of the variousembodiments described herein, even in cases where a particular elementis illustrated in each of the drawings that accompany the presentdescription. Further, it will be apparent that modifications andvariations are possible without departing from the scope of the presentdisclosure, including, but not limited to, embodiments defined in theappended claims. More specifically, although some aspects of the presentdisclosure are identified herein as preferred or particularlyadvantageous, it is contemplated that the present disclosure is notnecessarily limited to these aspects.

It is noted that one or more of the following claims utilize the term“wherein” as a transitional phrase. For the purposes of defining thepresent invention, it is noted that this term is introduced in theclaims as an open-ended transitional phrase that is used to introduce arecitation of a series of characteristics of the structure and should beinterpreted in like manner as the more commonly used open-ended preambleterm “comprising.”

What is claimed is:
 1. A materials handling vehicle operating systemcomprising a materials handling vehicle, a tag layout, and a tag readerresiding on the materials handling vehicle, wherein: the materialshandling vehicle comprises storage and retrieval hardware and a vehicledrive mechanism; the tag layout comprises a plurality of sequenced tagspositioned along a travel path comprising a restricted navigation zone;the sequenced tags comprise a plurality of entry/exit tag sets arrangedalong the travel path; each entry/exit tag set of the plurality ofentry/exit tag sets comprises a release tag, a restriction tag, and anindicator tag; the indicator tag is positioned between the restrictiontag and the restricted navigation zone along the travel path; and therestriction tag is positioned between the release tag and the indicatortag along the travel path.
 2. The system of claim 1 wherein theremediation operation is initiated when an indicator tag is identifiedout of sequence in the stored tag data.
 3. The system of claim 1 whereinthe remediation operation is initiated when: an indicator tag isidentified in direct sequence after a release tag is identified in thestored tag data and the materials handling vehicle is approaching therestricted navigation zone; an indicator tag is identified in directsequence after a restriction tag is identified in the stored tag dataand the materials handling vehicle is leaving the restricted navigationzone; or both.
 4. The system of claim 1 wherein: each entry/exit tag setof the plurality of entry/exit tag sets further comprises an additionalindicator tag; and the release tag is positioned between the restrictiontag and the additional indicator tag along the travel path.
 5. Thesystem of claim 1 wherein the remediation operation is initiated when anadditional indicator tag is identified out of sequence in the stored tagdata.
 6. The system of claim 1 wherein the remediation operation isinitiated when an additional indicator tag is identified in directsequence after a restriction tag is identified in the stored tag data.7. The system of claim 1 wherein the remediation operation is initiatedby generating a remediation signal.
 8. The system of claim 1 wherein theremediation operation comprises a fault signal generation step.
 9. Thesystem of claim 1 wherein the remediation operation comprises atransition to or from restricted or unrestricted operationalfunctionality of the materials handling vehicle.
 10. The system of claim1 wherein the remediation operation comprises a transition tooperational functionality that is based on a predicted commandassociated with a missing tag from the sequenced tags of the tag layout.11-13. (canceled)
 14. The system of claim 1 wherein the restrictednavigation zone is characterized by vehicle speed restrictions,materials handling height restrictions, or a combination thereof. 15.The system of claim 1 wherein the sequenced tags comprise RFID tags. 16.The system of claim 1 wherein the sequenced tags are distinguishableonly by tag identification data.
 17. The system of claim 1 wherein thesequenced tags are configured to provide identification data to the tagreader passively or actively.
 18. (canceled)
 19. A materials handlingvehicle operating system comprising a materials handling vehicle, a taglayout, and a tag reader residing on the materials handling vehicle,wherein: the materials handling vehicle comprises storage and retrievalhardware and a vehicle drive mechanism; the tag layout comprises aplurality of sequenced tags positioned along a travel path comprising arestricted navigation zone; the sequenced tags comprises an entry tagset and an exit tag set; the entry tag set comprises a restriction tagand an indicator tag; the exit tag set comprises a release tag; theindicator tag is positioned between the restriction tag and therestricted navigation zone along the travel path; and the restrictednavigation zone is positioned between the indicator tag and the releasetag along the travel path.
 20. The system of claim 19 wherein: the exittag set comprises the release tag and an additional indicator tag; andthe release tag is positioned between the restricted navigation zone andthe additional indicator tag along the travel path.
 21. A materialshandling vehicle tag layout comprising a plurality of sequenced tagspositioned along a travel path comprising a restricted navigation zone,wherein: the sequenced tags comprise a plurality of entry/exit tag setsarranged along the travel path; each entry/exit tag set of the pluralityof entry/exit tag sets comprises a release tag, a restriction tag, andan indicator tag; the indicator tag is positioned between therestriction tag and the restricted navigation zone along the travelpath; and the restriction tag is positioned between the release tag andthe indicator tag along the travel path.
 22. The tag layout of claim 21wherein: each entry/exit tag set of the plurality of entry/exit tag setsfurther comprises an additional indicator tag; and the release tag ispositioned between the restriction tag and the additional indicator tagalong the travel path.
 23. A materials handling vehicle tag layoutcomprising a plurality of sequenced tags positioned along a travel pathcomprising a restricted navigation zone, wherein: the sequenced tagscomprises an entry tag set arranged along the travel path and an exittag set arranged along the travel path; the entry tag set comprises arestriction tag and an indicator tag; the exit tag set comprises arelease tag; the indicator tag is positioned between the restriction tagand the restricted navigation zone along the travel path; and therestricted navigation zone is positioned between the indicator tag andthe release tag along the travel path.
 24. The tag layout of claim 23wherein: the exit tag set comprises the release tag and an additionalindicator tag; and the release tag is positioned between the restrictednavigation zone and the additional indicator tag along the travel path.25. A materials handling vehicle operating system comprising a materialshandling vehicle, a tag layout, a tag database, and a tag readerresiding on the materials handling vehicle, wherein: the materialshandling vehicle comprises storage and retrieval hardware and a vehicledrive mechanism; the tag layout comprises a plurality of sequenced tagspositioned along a travel path comprising a restricted navigation zone;the sequenced tags comprise a plurality of entry/exit tag sets arrangedalong the travel path; each entry/exit tag set of the plurality ofentry/exit tag sets comprises a release tag, a restriction tag, and anindicator tag; the tag database holds stored tag data identifying therelease tag, the restriction tag, and the indicator tag; the indicatortag is positioned between the restriction tag and the restrictednavigation zone along the travel path; and the restriction tag ispositioned between the release tag and the indicator tag along thetravel path.